An anode for a lithium-ion battery

Abstract

The application discloses a program control anilox roller adjusting method and system, relates to the field of gluing technology in the medicine aluminum-plastic blister packaging process, and is applied to the medicine aluminum-plastic blister packaging process and comprises the following steps: acquiring multi-source data in real time in the aluminum foil gluing process; calculating the actual flow index of a water-based adhesive in an anilox roller mesh hole according to the multi-source data and a preset operation rule; comparing the actual flow index with a preset target flow index; and adjusting the anilox roller operation parameters according to the deviation when the actual flow index deviates from the target flow index. The application can acquire multi-source data affecting the adhesive flow property in real time, calculate the actual flow index based on the data, accurately adjust the anilox roller operation parameters, effectively solve the gluing amount deviation and control lag problems caused by environmental changes and local temperature influences in the prior art, and significantly improve the gluing stability and packaging quality.

Description

Technical Field

[0001] This application relates to the field of adhesive coating technology in the aluminum-plastic blister packaging process for pharmaceuticals, and more specifically, to a program-controlled anilox roller adjustment method and system. Background Technology

[0002] In pharmaceutical packaging, particularly in the aluminum-plastic blister packaging process, precise control of the adhesive application process is crucial for ensuring product quality and integrity. Typically, production lines use programmed anilox rollers to apply the adhesive. Under ideal conditions, this method achieves a high degree of automation and consistency. However, in real-world production environments, unpredictable factors such as ambient temperature fluctuations and the temperature sensitivity of novel adhesives often pose challenges to this precise control. Existing control systems often struggle to respond to these changes accurately and in real time, leading to deviations in adhesive application and consequently affecting the packaging's sealing effect.

[0003] One of the key processes in aluminum-plastic blister packaging is the heat-sealing of aluminum foil and molded PVC sheets using adhesive. To precisely control the amount of adhesive applied to the aluminum foil, anilox roller coating technology is commonly used on production lines. The entire production line's control system, such as a programmable logic controller (PLC), pre-stores process parameters for different pharmaceutical packaging specifications. When a production order is placed, the operator selects the corresponding product model on the control panel, and the control system immediately calls the preset program, automatically adjusting the pressure between the anilox roller and the printing roller, the rotation speed of the anilox roller, and the angle and pressure of the doctor blade. This programmed control ensures that the anilox roller stably obtains adhesive from the adhesive tray and, through its tiny pores, transfers a uniformly thick and precisely measured adhesive film to the area of ​​the aluminum foil to be sealed. Under ideal operating conditions, this program-based control method can continuously produce pharmaceutical packaging with satisfactory sealing performance.

[0004] However, in actual production, the ambient temperature in the workshop fluctuates with seasonal changes and diurnal temperature variations. Using water-based adhesives, whose fluidity is highly sensitive to temperature changes, presents a problem: when the workshop temperature is low in the early morning, the adhesive viscosity increases, and its fluidity decreases. At this time, even if the control program executes standard parameters, the amount of adhesive carried by the anilox roller from the adhesive tray will exceed the preset value due to the increased viscosity, resulting in excessive adhesive application. Conversely, in the afternoon, the overall temperature rises due to prolonged equipment operation, causing the adhesive viscosity to decrease and its fluidity to increase. Under the same program parameters, the amount of adhesive transferred by the anilox roller will be less than the standard value. This fluctuation in adhesive application caused by ambient temperature changes directly leads to unstable sealing quality of pharmaceutical packaging, resulting in partial seal defects or adhesive overflow, increasing the defect rate.

[0005] To address this issue, technicians installed an online viscosity detector on the adhesive supply line and attempted to feed the detected viscosity information back to the main control system, establishing a closed-loop control logic. However, during actual debugging, they discovered a control lag. There is a physical distance between the location of the viscosity detector and the adhesive's final transfer to the aluminum foil by the anilox roller. The adhesive needs to flow through the pipe, into the adhesive tray, and then be carried by the anilox roller. This time asynchrony causes the control system to always be a step behind, failing to stabilize the adhesive application rate and potentially leading to more drastic and irregular fluctuations in the application rate due to frequent over- or under-adjustments.

[0006] Furthermore, during continuous high-speed production, the surface temperature of the anilox roller gradually rises due to continuous friction with the doctor blade and rolling contact with the printing plate roller, sometimes significantly exceeding the ambient temperature of the workshop. This creates a localized high-temperature zone. The viscosity detector located in the adhesive supply line can only measure the macroscopic viscosity of the main adhesive, but cannot detect the secondary viscosity decrease caused by the heat generated by the roller itself within the thin layer of adhesive in the cells on the anilox roller surface. Existing single-point viscosity feedback control systems completely fail to consider the immediate impact of the localized temperature on the anilox roller surface on the adhesive state.

[0007] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0008] This application discloses a program-controlled anilox roller adjustment method and system, which aims to solve the problems of adhesive application deviation and control lag caused by ambient temperature fluctuations, the temperature sensitivity of new adhesives, and local temperature rise of the anilox roller in the pharmaceutical aluminum-plastic blister packaging process.

[0009] The technical solution of this application is as follows:

[0010] In a first aspect, this application discloses a program-controlled anilox roller adjustment method applied to pharmaceutical aluminum-plastic blister packaging processes, comprising:

[0011] The following multi-source data are acquired in real time during the aluminum foil coating process: viscosity of water-based adhesive in the adhesive tube, ambient temperature, temperature of water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed.

[0012] Based on multi-source data and preset calculation rules, the actual flow index of water-based adhesive in the anilox roller cells is calculated.

[0013] Compare the actual flow index with the preset target flow index;

[0014] When there is a deviation between the actual flow index and the target flow index, the operating parameters of the anilox roller are adjusted according to the magnitude of the deviation.

[0015] This technical solution enables the real-time acquisition of multi-source data affecting adhesive flowability, and the calculation of the actual flow index based on this data, thereby achieving precise adjustment of the anilox roller operating parameters. It effectively solves the problems of adhesive application deviation and control lag caused by environmental changes and local temperature effects in the existing technology, and significantly improves the stability of adhesive application and packaging quality.

[0016] Furthermore, in the above-mentioned program-controlled anilox roller adjustment method, after the step of adjusting the anilox roller operating parameters according to the magnitude of the deviation when there is a deviation between the actual flow index and the target flow index, the method further includes:

[0017] Obtain an image of the coated area at the edge of the aluminum foil after the coating process is completed, corresponding to the adjustment of the anilox roller's operating parameters.

[0018] Calculate the adhesive width at the edge of the aluminum foil based on the image of the adhesive-coated area;

[0019] Calculate the difference in glue application amount between the glue application width and the preset glue application standard width, and determine whether the difference in glue application amount is within the preset range;

[0020] When the difference in adhesive application amount is outside the preset range, the operating parameters of the anilox roller are adaptively adjusted according to the magnitude of the difference in adhesive application amount, so that the difference in adhesive application amount between the edge of the aluminum foil after subsequent adhesive application and the preset standard adhesive application width falls back to within the preset range.

[0021] Through this technical solution, after initial adjustment, the system can perform secondary verification and adaptive correction of the glue application effect through image recognition and glue application width calculation, further ensuring that the glue application amount accurately meets the standard, effectively avoiding quality problems caused by insufficient or excessive adjustment at one time, and improving the precision of control.

[0022] Based on the above, this application further proposes that, when the aluminum foil coating process is stable and the difference in coating amount between the coating width at the edge of the aluminum foil and the preset coating standard width is within a preset range, the following operations are performed periodically at set intervals:

[0023] The operating parameters of the anilox roller are fine-tuned according to the preset exploratory disturbance rules;

[0024] Obtain an image of the first coated area at the edge of the first aluminum foil after the coating process is completed, corresponding to the fine-tuning of the anilox roller's operating parameters.

[0025] Calculate the first adhesive width at the edge of the first aluminum foil based on the image of the first adhesive-coated area;

[0026] Calculate the difference in the first adhesive application amount between the first adhesive application width and the preset standard adhesive application width;

[0027] Compare the difference in the first amount of adhesive applied, the width of the adhesive applied to the edge of the aluminum foil before fine-tuning, and the difference in the second amount of adhesive applied to the preset standard width.

[0028] Adjust the adjustment coefficient used to calculate the actual flow index based on the difference between the first and second adhesive application amounts.

[0029] Through this technical solution, the system can dynamically optimize the adjustment coefficient of the actual flow index under stable operation through periodic exploratory fine-tuning and effect evaluation. This enables the control model to learn and adapt to long-term subtle changes in the production environment, thereby achieving deeper optimization and more lasting stability.

[0030] In some preferred embodiments, the step of obtaining the temperature of the water-based adhesive in the adhesive tray in real time during the aluminum foil coating process specifically includes:

[0031] The first radiation intensity value of the water-sensitive infrared band, the second radiation intensity value of the polymer-sensitive infrared band, and the third radiation intensity value of the substrate reference infrared band were collected from the adhesive tray.

[0032] Based on the first radiation intensity value, the second radiation intensity value, and the third radiation intensity value, calculate the activity index of the water-based adhesive and the presence index of the water-based adhesive residual layer.

[0033] The true temperature of the water-based adhesive in the adhesive tray is calculated based on the activity index and the residual layer presence index of the water-based adhesive.

[0034] The actual temperature of the water-based adhesive inside the glue tray is defined as the temperature of the water-based adhesive inside the glue tray.

[0035] This technical solution enables the accurate acquisition and calculation of the true temperature of the water-based adhesive in the glue tray by collecting and calculating the multi-band infrared radiation intensity values. It overcomes the measurement errors and hysteresis that may exist in traditional temperature sensors, providing a more accurate input for the calculation of the actual flow index, thereby improving the overall control accuracy.

[0036] Based on the above, this application also proposes that the multi-source data also include the anilox roller operating parameters;

[0037] After acquiring multi-source data in real time during the aluminum foil coating process, the following is also included:

[0038] Each data point in the multi-source data is decomposed, and the minute fluctuation components of each data point are extracted. All the minute fluctuation components are summarized to obtain the natural pulsation characteristics in the aluminum foil coating process.

[0039] Based on the natural pulsation characteristics, find the matching third glue amount difference from the mapping relationship between natural pulsation characteristics and glue amount difference;

[0040] Adjust the adjustment coefficient used to calculate the actual flow index based on the difference in the third coating amount.

[0041] Through this technical solution, the system can identify and utilize the natural pulsation characteristics in the production process. By using a pre-established mapping relationship, it can predict and compensate for the impact of these minute fluctuations on the amount of adhesive applied, thereby improving the robustness and accuracy of control at a more subtle level and effectively dealing with random disturbances in the production process.

[0042] Furthermore, the steps for establishing the mapping relationship between natural pulsation characteristics and the difference in adhesive application amount include:

[0043] Each historical data point obtained from the historical multi-source data in the historical aluminum foil coating process is decomposed, and the minute fluctuation components of each historical data point are extracted. All the minute fluctuation components are summarized to obtain the first natural pulsation feature in the historical aluminum foil coating process.

[0044] For each first natural pulsation feature, obtain the image of the second adhesive-coated area at the edge of the second aluminum foil after adhesive coating is completed;

[0045] Calculate the second adhesive width at the edge of the second aluminum foil based on the image of the second adhesive-coated area;

[0046] Calculate the difference in fourth adhesive application amount between the second adhesive application width and the preset standard adhesive application width;

[0047] Establish a one-to-one correspondence between each first natural pulsation feature and the corresponding fourth adhesive amount difference to obtain the mapping relationship between natural pulsation feature and adhesive amount difference.

[0048] This technical solution establishes a mapping relationship between natural pulsation characteristics and the difference in adhesive application amount through in-depth mining and analysis of historical data. This provides a data foundation for real-time prediction and compensation of minor fluctuations in the production process, enabling the system to learn from historical experience and optimize control strategies.

[0049] Based on the above, this application further proposes that, after adjusting the adjustment coefficient used to calculate the actual flow index according to the magnitude of the third coating amount difference, the method further includes:

[0050] Calculate the current actual flow index of the water-based adhesive in the anilox roller cells based on the adjusted adjustment coefficient;

[0051] Compare the current actual liquidity index with the preset target liquidity index;

[0052] If there is a first deviation between the current actual flow index and the target flow index, the operating parameters of the anilox roller will be adjusted according to the magnitude of the first deviation.

[0053] With this technical solution, after adjusting the adjustment coefficient according to the natural pulsation characteristics, the system will recalculate the actual flow index and compare it with the target value. If there is still a deviation, the operating parameters of the anilox roller will be adjusted again to form a more refined closed-loop control, ensuring that the target coating amount can be quickly converged even under complex fluctuations.

[0054] In some preferred embodiments, the natural pulsation characteristics include minute fluctuations in instantaneous frequency, amplitude, and phase stripped out within a set time window from at least one of the following data: viscosity of the water-based adhesive in the hose, ambient temperature, temperature of the water-based adhesive in the reel, local temperature of the anilox roller, and operating parameters of the anilox roller.

[0055] This technical solution clarifies the specific composition of natural pulsation characteristics, namely, the minute fluctuation components such as instantaneous frequency, amplitude, and phase extracted from multi-source data. This enables the system to capture dynamic changes in the production process more comprehensively and precisely, providing richer and more accurate information for subsequent prediction and compensation.

[0056] Based on the above, this application also proposes that the preset calculation rule is: Actual flow index = viscosity of water-based adhesive in hose × (1 + C1 × (temperature of water-based adhesive in rubber tray - temperature of water-based adhesive in target rubber tray)) × (1 + C2 × (local temperature of anilox roller - local temperature of target anilox roller)) × (1 + C3 × (ambient temperature - target ambient temperature)) + C4 × production line speed;

[0057] C1, C2, C3, and C4 are adjustment coefficients used to calculate the actual flow index.

[0058] This technical solution provides a specific actual flow index calculation model that includes multiple key influencing factors. By introducing adjustment coefficients C1, C2, C3, and C4, the model becomes adjustable and adaptable, and can be optimized according to actual working conditions, thereby more accurately reflecting the true flow state of the adhesive in the anilox roller cells.

[0059] Secondly, this application also discloses a program-controlled anilox roller adjustment system applied to pharmaceutical aluminum-plastic blister packaging processes, comprising:

[0060] The acquisition module is used to acquire the following multi-source data in real time during the aluminum foil coating process: viscosity of water-based adhesive in the adhesive tube, ambient temperature, temperature of water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed.

[0061] The calculation module is used to calculate the actual flow index of water-based adhesive in the anilox roller cells based on multi-source data and preset calculation rules;

[0062] The comparison module is used to compare the actual flow index with the preset target flow index.

[0063] The adjustment module is used to adjust the operating parameters of the anilox roller according to the magnitude of the deviation between the actual flow index and the target flow index.

[0064] This technical solution provides a system for implementing the above methods. Through modular design, it can efficiently integrate multi-source data acquisition, flow index calculation, deviation comparison, and parameter adjustment functions, providing a stable and accurate adhesive control solution for pharmaceutical aluminum-plastic blister packaging processes.

[0065] Beneficial effects

[0066] This application discloses a program-controlled anilox roller adjustment method. During the aluminum foil coating process, it acquires multi-source data in real time, including the viscosity of the water-based adhesive in the adhesive tube, ambient temperature, temperature of the water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed. Based on this data and preset calculation rules, it calculates the actual flow index of the water-based adhesive within the cells of the anilox roller. Subsequently, it compares the actual flow index with a preset target flow index. When a deviation exists, the system adjusts the anilox roller's operating parameters according to the magnitude of the deviation. This method effectively solves the problems in existing technologies where fluctuations in ambient temperature, the temperature sensitivity of novel adhesives, and local temperature increases caused by the anilox roller's own heating lead to changes in adhesive viscosity, resulting in coating amount deviations and control lag. Through real-time, multi-dimensional parameter sensing and dynamic adjustment based on the actual flow index, this application overcomes the limitations of traditional single-point viscosity feedback control, avoids coating amount fluctuations caused by control lag and local temperature effects, significantly improves the accuracy and stability of coating in pharmaceutical aluminum-plastic blister packaging processes, thereby reducing defect rates and ensuring product quality. Attached Figure Description

[0067] Figure 1 This application provides a schematic flowchart of a program-controlled anilox roller adjustment method.

[0068] Figure 2 This application provides a schematic diagram of a program-controlled anilox roller adjustment system.

[0069] Figure 2 In the diagram: 1 is the acquisition module, 2 is the calculation module, 3 is the comparison module, and 4 is the adjustment module. Detailed Implementation

[0070] The technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments.

[0071] See Figure 1 This application proposes a program-controlled anilox roller adjustment method for pharmaceutical aluminum-plastic blister packaging, comprising:

[0072] S10. In the aluminum foil coating process, acquire the following multi-source data in real time: viscosity of water-based adhesive in the adhesive tube, ambient temperature, temperature of water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed.

[0073] S20. Calculate the actual flow index of the water-based adhesive in the anilox roller cavity based on the multi-source data and preset calculation rules.

[0074] S30. Compare the actual flow index with the preset target flow index;

[0075] S40. When there is a deviation between the actual flow index and the target flow index, the operating parameters of the anilox roller shall be adjusted according to the magnitude of the deviation.

[0076] This application aims to provide a more precise and real-time anilox roller adjustment method to address the challenges of adhesive application control in pharmaceutical aluminum-plastic blister packaging processes. By comprehensively considering multi-source data and introducing the concept of actual flow index, this method achieves accurate assessment of the true state of water-based adhesives within the anilox roller cells. This allows for timely and effective adjustment of the anilox roller's operating parameters, ensuring the stability and consistency of adhesive application, and significantly improving product quality and production efficiency.

[0077] In the aluminum-plastic blister packaging process for pharmaceuticals, the anilox roller is a key coating device. Its surface is engraved with numerous tiny cells for precisely transferring water-based adhesives. Water-based adhesives use water as a dispersion medium, and their viscosity is significantly affected by temperature. The viscosity of the water-based adhesive in the tubing refers to its macroscopic viscosity within the adhesive supply line. Ambient temperature refers to the air temperature within the production workshop. The temperature of the water-based adhesive in the adhesive tray refers to the temperature of the adhesive in the tray into which the anilox roller is immersed. The local temperature of the anilox roller refers to the instantaneous temperature of the area where the anilox roller surface rubs against the doctor blade and contacts the printing plate roller. The production line speed refers to the speed at which the aluminum foil passes through the coating process. The actual flow index is a comprehensive indicator characterizing the flow performance of the water-based adhesive within the cells of the anilox roller; it reflects the true state of the adhesive at the moment of coating. The target flow index is a preset, ideal adhesive flow performance indicator. Anilox roller operating parameters include, but are not limited to, anilox roller speed, pressure between the anilox roller and the printing plate roller, doctor blade angle and pressure, etc. These parameters directly affect the amount of adhesive transferred.

[0078] In the aluminum foil coating process, real-time acquisition of multi-source data is fundamental to achieving precise control. The viscosity of the water-based adhesive inside the tubing can be measured in real time using online viscosity sensors; for example, sensors can be installed in the adhesive supply line, utilizing vibration or rotation principles to detect viscosity changes. Ambient temperature can be monitored in real time by deploying multiple temperature sensors throughout the workshop, and the average value or temperature values ​​of key areas can be recorded. The temperature of the water-based adhesive in the adhesive tray can be measured in real time using an immersion temperature probe, ensuring full contact between the probe and the adhesive. The local temperature of the anilox roller can be obtained using a non-contact infrared thermometer, which can focus on key areas on the surface of the anilox roller to acquire its temperature data in real time. Production line speed can be detected in real time using encoders or speed sensors installed on the production line. This data is collected in real time and transmitted to the control system, providing a basis for subsequent calculations and adjustments.

[0079] Based on the acquired multi-source data and preset calculation rules, the actual flow index of the water-based adhesive within the anilox roller cells is calculated. The preset calculation rules can be a mathematical model or algorithm that comprehensively considers the effects of the adhesive viscosity in the hose, ambient temperature, adhesive temperature in the reel, local temperature of the anilox roller, and production line speed on the adhesive's flowability. For example, the calculation rule can be a multivariate function, where each variable has a corresponding adjustment coefficient to reflect its contribution to the flow index. By substituting the real-time acquired multi-source data into this calculation rule, the actual flow index of the water-based adhesive within the anilox roller cells under the current operating conditions can be obtained.

[0080] The calculated actual flow index is then compared with the preset target flow index. The target flow index is an ideal value preset based on product quality requirements and process experience; it represents the flow performance of the adhesive under optimal application conditions. The comparison can be achieved through simple numerical difference calculations or by setting an allowable deviation range.

[0081] When the actual flow index deviates from the target flow index, the operating parameters of the anilox roller are adjusted according to the magnitude of the deviation. The purpose of the adjustment is to bring the actual flow index closer to the target flow index. For example, if the actual flow index is higher than the target flow index, it indicates that the adhesive is too fluid, which may result in insufficient adhesive application. In this case, the pressure between the anilox roller and the printing plate roller can be appropriately increased, or the speed of the anilox roller can be decreased to increase the amount of adhesive transferred. Conversely, if the actual flow index is lower than the target flow index, it indicates that the adhesive is not fluid enough, which may result in excessive adhesive application. In this case, the pressure between the anilox roller and the printing plate roller can be appropriately decreased, or the speed of the anilox roller can be increased to reduce the amount of adhesive transferred. The adjustment strategy can employ a proportional-integral-derivative (PID) control algorithm to dynamically adjust the operating parameters of the anilox roller based on the magnitude and trend of the deviation, thereby achieving precise control.

[0082] This application's program-controlled anilox roller adjustment method acquires multi-source data in real time during the aluminum foil coating process, including the viscosity of the water-based adhesive in the adhesive tube, ambient temperature, temperature of the water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed. Based on this data and preset calculation rules, the system calculates the actual flow index of the water-based adhesive within the cells of the anilox roller, thus accurately reflecting the true state of the adhesive at the moment of coating. When the actual flow index deviates from the preset target flow index, the system can promptly adjust the anilox roller operating parameters according to the magnitude of the deviation. This method overcomes the lag problem of single-point viscosity feedback control in existing technologies and fully considers the influence of local temperature on adhesive flowability, resulting in more precise and real-time control of the coating amount.

[0083] Compared to traditional control methods that rely solely on preset programs or single viscosity feedback, the solution presented in this application offers significant advantages. Traditional methods often fail to adjust the adhesive application amount accurately and promptly when faced with complex operating conditions such as fluctuating ambient temperatures and localized heating of the anilox roller, leading to unstable product quality. For example, in low workshop temperatures, traditional methods may result in excessive adhesive application due to increased viscosity; conversely, when the localized temperature of the anilox roller rises, it may result in insufficient adhesive application due to decreased viscosity. This application, by introducing multi-source data and the concept of actual flow index, can more comprehensively and accurately assess the true flow state of the adhesive, thereby achieving more refined control. This method not only effectively solves the problem of adhesive application fluctuations, improving the sealing quality and pass rate of pharmaceutical packaging, but also reduces waste caused by defective products, enhancing production efficiency and economic benefits. Therefore, this application represents a significant technological advancement in the field of adhesive application control for pharmaceutical aluminum-plastic blister packaging processes.

[0084] This application further proposes a scheme to adaptively correct the anilox roller operating parameters after adjusting the operating parameters of the anilox roller by acquiring an image of the coated area at the edge of the coated aluminum foil, calculating the coating width and comparing it with a preset coating standard width, and when the difference in coating amount exceeds the preset range.

[0085] Specifically, after adjusting the anilox roller operating parameters according to the magnitude of the deviation when there is a discrepancy between the actual flow index and the target flow index, the process also includes:

[0086] Obtain an image of the coated area at the edge of the aluminum foil after the coating process is completed, corresponding to the adjustment of the anilox roller's operating parameters.

[0087] Calculate the adhesive width at the edge of the aluminum foil based on the image of the adhesive-coated area;

[0088] Calculate the difference in glue application amount between the glue application width and the preset glue application standard width, and determine whether the difference in glue application amount is within the preset range;

[0089] When the difference in adhesive application amount is outside the preset range, the operating parameters of the anilox roller are adaptively modified according to the magnitude of the difference in adhesive application amount, so that the difference in adhesive application amount between the edge of the aluminum foil after subsequent adhesive application and the preset standard adhesive application width falls back to within the preset range.

[0090] Specifically, "acquiring an image of the coated area at the edge of the aluminum foil after adhesive coating has been applied, corresponding to the adjustment of the anilox roller's operating parameters" refers to capturing image data of the coated aluminum foil edge in real time using a vision inspection system or industrial camera after the anilox roller's operating parameters have been initially adjusted. This image data contains the actual morphological information of the coated area and serves as a direct basis for evaluating the coating quality.

[0091] "Calculating the adhesive width at the edge of the aluminum foil based on the adhesive-coated area image" refers to using image processing techniques to analyze the acquired adhesive-coated area image. For example, algorithms such as edge detection, region segmentation, and pixel counting can be used to accurately measure the actual adhesive width at the edge of the aluminum foil. This step aims to transform visual information into quantifiable numerical indicators.

[0092] "Calculating the difference in glue application amount between the actual glue application width and the preset standard glue application width, and determining whether the difference in glue application amount is within the preset range" refers to comparing the calculated actual glue application width with a preset standard glue application width that meets product quality requirements, and obtaining the difference between the two, i.e., the glue application amount difference. Subsequently, this difference in glue application amount is compared with a preset allowable range to determine whether the current glue application quality is qualified. The preset range is usually determined according to process requirements and product standards, and is used to define acceptable glue application deviations.

[0093] "When the difference in adhesive application amount is outside the preset range, the operating parameters of the anilox roller are adaptively adjusted according to the magnitude of the difference, so that the difference in adhesive application amount between the edge of the aluminum foil after subsequent adhesive application and the preset standard width falls back within the preset range." This means that when the difference in adhesive application amount is detected to exceed the preset allowable range, the system will intelligently adjust the operating parameters of the anilox roller, such as the linear speed, pressure, and scraper angle, based on the specific magnitude and direction of the difference. This correction is a feedback-based adaptive adjustment, the purpose of which is to ensure that the subsequent adhesive application process can control the adhesive application width within the preset standard range, thereby guaranteeing product quality.

[0094] This application's solution overcomes the shortcomings of relying solely on internal parameters for adjustment by introducing a direct measurement and feedback mechanism for the final coating effect. After the anilox roller's operating parameters are initially adjusted based on the flow index, the system further obtains the actual coating width using image recognition technology and compares it with the standard width. If the coating amount difference exceeds the preset range, it indicates that the initial adjustment has not fully achieved the ideal coating effect. At this point, the system will perform a secondary, adaptive parameter correction based on the actual deviation. This correction mechanism enables the coating process to respond to external disturbances or internal changes that may occur in actual production and are not fully captured by the flow index model, thereby ensuring the stability and consistency of coating quality.

[0095] Through the above technical solution, this application enables more precise control over the adhesive coating width of aluminum foil in the aluminum-plastic blister packaging process for pharmaceuticals. This solution monitors the adhesive coating area image at the edge of the coated aluminum foil in real time and adaptively corrects the anilox roller operating parameters based on image analysis results, effectively avoiding coating quality problems caused by limitations of the flow index model or changes in the external environment. This significantly improves the accuracy and stability of adhesive coating, reduces the scrap rate, ensures the sealing and safety of pharmaceutical packaging, and ultimately enhances overall production efficiency and product quality.

[0096] This application further proposes a method for optimizing the above-mentioned adjustment coefficient, specifically including:

[0097] When the aluminum foil coating process is stable and the difference in coating amount between the coating width at the edge of the aluminum foil and the preset coating standard width is within a preset range, perform the following operations periodically at set intervals:

[0098] The operating parameters of the anilox roller are fine-tuned according to the preset exploratory disturbance rules;

[0099] Obtain an image of the first coated area at the edge of the first aluminum foil after the coating process is completed, corresponding to the fine-tuning of the anilox roller's operating parameters.

[0100] Calculate the first adhesive width at the edge of the first aluminum foil based on the image of the first adhesive-coated area;

[0101] Calculate the difference in the first adhesive application amount between the first adhesive application width and the preset standard adhesive application width;

[0102] Compare the difference in the first amount of adhesive applied, the width of the adhesive applied to the edge of the aluminum foil before fine-tuning, and the difference in the second amount of adhesive applied to the preset standard width.

[0103] Adjust the adjustment coefficient used to calculate the actual flow index based on the difference between the first and second adhesive application amounts.

[0104] Specifically, when the aluminum foil coating process is determined to be in a stable state, it usually means that the key parameters of the production line fluctuate little over a period of time, and the coating quality (such as coating width) has reached or is close to the preset standard, with the difference in coating amount between the coating width and the preset standard being within the preset allowable range. During this stable operation period, the system will periodically perform a series of optimization operations at preset time intervals, such as every few minutes or hours.

[0105] Fine-tuning the anilox roller's operating parameters according to preset exploratory perturbation rules refers to making small, directional adjustments to certain operating parameters of the anilox roller, such as its rotational speed, pressure, or temperature, without significantly affecting current production quality. These perturbation rules can be preset to detect the system's response to these minute changes, thereby collecting more information about the system's dynamic behavior.

[0106] Furthermore, after the anilox roller's operating parameters are fine-tuned, the system acquires an image of the first coated area at the edge of the first aluminum foil after coating, and calculates the first coating width at the edge of the first aluminum foil based on this image. Subsequently, this first coating width is compared with a preset standard coating width to calculate the first coating amount difference. Simultaneously, the system records a second coating amount difference between the coating width at the edge of the aluminum foil before fine-tuning and the preset standard coating width as a benchmark.

[0107] Therefore, by comparing the difference in the first coating amount with the difference in the second coating amount, the system can assess the impact of this fine-tuning on the coating quality. For example, if the difference in the first coating amount decreases relative to the difference in the second coating amount (i.e., the coating width is closer to the standard), it indicates that the fine-tuning is positive; conversely, if the difference increases, it indicates that the fine-tuning effect is poor. Based on this comparison result, the system will intelligently adjust the adjustment coefficients used to calculate the actual flow index. For example, gradient descent, reinforcement learning, or other optimization algorithms can be used to update these coefficients so that the calculation of the actual flow index more accurately reflects the current coating state and process requirements.

[0108] This application's solution introduces exploratory disturbances during the stable operation of the aluminum foil coating process and adjusts the regulation coefficient of the actual flow index based on the change in the difference in coating amount before and after the disturbance. This solves the problem that the preset calculation rules in the basic solution may not be fully adaptable to subtle changes during long-term operation. Specifically, when the coating process is in a stable state, the system does not simply maintain the existing parameters but actively performs small-scale "experimental" fine-tuning. These fine-tunings aim to explore the potential relationship between the current process parameters and the optimal coating effect. By comparing the difference in coating amount before and after the fine-tuning, the system can quantify the actual impact of each fine-tuning on the coating quality. For example, if the fine-tuning reduces the difference in coating amount, it indicates that the parameter adjustment in that direction is positive, and the system will correspondingly adjust the regulation coefficient in the actual flow index calculation formula to strengthen this positive correlation. Conversely, if the fine-tuning leads to an increase in the difference in coating amount, the system will adjust the regulation coefficient to weaken or reverse this correlation. This adaptive adjustment mechanism enables the calculation model of the actual flow index to be dynamically optimized with subtle changes in the production environment, thereby ensuring that even during long-term operation, the system can continuously calculate the actual flow index in a more accurate manner and adjust the anilox roller operating parameters more effectively accordingly.

[0109] Through the above technical solution, this application achieves adaptive optimization of the anilox roller adjustment method. When the process is stable, this solution, through periodic exploratory disturbances and effect evaluations, allows the adjustment coefficient used to calculate the actual flow index to be dynamically adjusted based on actual production feedback. This significantly improves the accuracy and robustness of the actual flow index calculation, enabling it to better adapt to subtle changes or long-term drifts that may occur during production that are not directly monitored. Therefore, this application can not only correct existing deviations but also proactively learn and optimize the control model, thereby continuously maintaining or improving coating quality during long-term operation, reducing reliance on manual experience, and effectively avoiding potential quality problems caused by the failure of fixed-parameter models, further improving the stability and economic benefits of pharmaceutical aluminum-plastic blister packaging processes.

[0110] Specifically, in some embodiments of the above-mentioned program-controlled anilox roller adjustment method, the step of obtaining the temperature of the water-based adhesive in the adhesive tray in real time during the aluminum foil coating process can be further refined.

[0111] Specifically, the steps for real-time monitoring of the temperature of the water-based adhesive in the adhesive tray during the aluminum foil coating process include:

[0112] The first radiation intensity value of the water-sensitive infrared band, the second radiation intensity value of the polymer-sensitive infrared band, and the third radiation intensity value of the substrate reference infrared band were collected from the adhesive tray.

[0113] Based on the first radiation intensity value, the second radiation intensity value, and the third radiation intensity value, calculate the activity index of the water-based adhesive and the presence index of the water-based adhesive residual layer.

[0114] The true temperature of the water-based adhesive in the adhesive tray is calculated based on the activity index and the residual layer presence index of the water-based adhesive.

[0115] The actual temperature of the water-based adhesive in the glue tray is defined as the temperature of the water-based adhesive in the glue tray.

[0116] The water-sensitive infrared band within the adhesive tray refers to a specific range of infrared wavelengths with high absorption or emission characteristics for water molecules in water-based adhesives. By collecting the first radiation intensity value of this band, the content or state of water molecules in the water-based adhesive can be reflected. The polymer-sensitive infrared band refers to a specific range of infrared wavelengths with high absorption or emission characteristics for polymer components in water-based adhesives. By collecting the second radiation intensity value of this band, the content or state of polymers in the water-based adhesive can be reflected. The substrate reference infrared band refers to the range of infrared wavelengths used to provide background or benchmark reference. By collecting the third radiation intensity value of this band, the influence of environmental interference or equipment errors on the measurement results can be eliminated. The water-based adhesive activity index can be understood as reflecting the activity level or concentration of active ingredients (such as water and some polymers) in the water-based adhesive. Its calculation can be based on the first and second radiation intensity values. The water-based adhesive residual layer presence index can be understood as an indicator reflecting the thickness or coverage of the water-based adhesive layer within the adhesive tray. Its calculation can be based on the first, second, and third radiation intensity values. By comprehensively considering these radiation intensity values, the physicochemical state of the water-based adhesive can be assessed more accurately. The calculation of the true temperature of the water-based adhesive within the adhesive tray is based on the water-based adhesive activity index and the water-based adhesive residual layer presence index. These indices provide detailed information about the adhesive composition and state, allowing the temperature calculation to exclude interference from other factors and obtain a temperature value closer to reality. Finally, the calculated true temperature of the water-based adhesive within the adhesive tray is defined as the water-based adhesive temperature within the adhesive tray, and is used for subsequent calculations of the actual flow index and adjustment of the anilox roller operating parameters.

[0117] This application's solution, by collecting radiation intensity values ​​in different infrared bands, can distinguish the influence of water, polymers, and environmental background in water-based adhesives. Specifically, the first radiation intensity value is used to characterize the water content, the second radiation intensity value is used to characterize the polymer content, and the third radiation intensity value serves as a benchmark reference for calibration and elimination of interference from non-adhesive components. Therefore, by calculating the water-based adhesive activity index and the water-based adhesive residual layer presence index, the actual state of the water-based adhesive can be more comprehensively reflected, including its component ratio and layer thickness. It is precisely because these indices provide more refined adhesive state information that the calculation of the true temperature of the water-based adhesive in the adhesive tray can eliminate errors that may exist in traditional temperature measurement methods, such as measurement deviations caused by changes in adhesive composition or uneven layer thickness, thus obtaining more accurate temperature data. This method based on multi-band infrared radiation analysis ensures high accuracy and high reliability in real-time acquisition of the water-based adhesive temperature in the adhesive tray, even in complex coating processes.

[0118] The above technical solution enables accurate and real-time acquisition of the temperature of water-based adhesives within the adhesive tray. Compared to traditional contact or single-band infrared thermometry methods, this solution effectively avoids measurement errors caused by factors such as complex adhesive composition, layer thickness variations, or environmental interference by introducing water-sensitive, polymer-sensitive, and substrate-referenced infrared radiation intensity values, combined with the calculation of activity index and residual layer presence index. As a result, the obtained true temperature data of the water-based adhesive within the adhesive tray is more accurate and reliable, providing a solid foundation for the accurate calculation of the actual flow index, thereby improving the precision and effectiveness of anilox roller operating parameter adjustment, and ultimately contributing to the stability of adhesive coating quality in pharmaceutical aluminum-plastic blister packaging processes.

[0119] This application further proposes that the aforementioned multi-source data also includes anilox roller operating parameters; after acquiring multi-source data in real time during the aluminum foil coating process, it also includes:

[0120] Each data point in the multi-source data is decomposed, and the minute fluctuation components of each data point are extracted. All the minute fluctuation components are summarized to obtain the natural pulsation characteristics in the aluminum foil coating process.

[0121] Based on the natural pulsation characteristics, a matching third glue application amount difference is found from the mapping relationship between natural pulsation characteristics and glue application amount difference;

[0122] Adjust the adjustment coefficient used to calculate the actual flow index based on the difference in the third coating amount.

[0123] Specifically, the scope of the multi-source data has been expanded to include anilox roller operating parameters. This means that when acquiring data in real time, in addition to the viscosity of the water-based adhesive in the hose, the ambient temperature, the temperature of the water-based adhesive in the reel, the local temperature of the anilox roller, and the production line speed, the current operating parameters of the anilox roller (such as rotational speed and pressure) are also taken into consideration, thereby providing more comprehensive process information for subsequent analysis.

[0124] The process of decomposing each type of data from multiple sources to extract its subtle fluctuations involves performing signal processing or time series analysis on the real-time acquired data to identify and extract non-periodic, low-amplitude instantaneous changes or random disturbances. These subtle fluctuations may reflect minute dynamic changes within the process. Subsequently, all these extracted subtle fluctuations are summarized to comprehensively characterize the overall natural pulsation characteristics of the aluminum foil coating process over a specific time period. These natural pulsation characteristics reflect inherent properties of the process and may be potentially related to minor deviations in the coating amount.

[0125] In practical applications, finding the matching third adhesive application amount difference from the mapping relationship between natural pulsation features and adhesive application amount difference based on the natural pulsation features refers to utilizing a pre-established mapping relationship that reflects the correlation between natural pulsation features and adhesive application amount deviation. This mapping relationship can be a lookup table, a mathematical model, or a machine learning model, and its purpose is to predict or correlate possible adhesive application amount deviations, i.e., the third adhesive application amount difference, based on the currently detected natural pulsation features.

[0126] Therefore, the adjustment coefficient used to calculate the actual flow index is adjusted based on the magnitude of the third coating amount difference. This means that when a specific natural pulsation characteristic is detected and the corresponding coating amount deviation is predicted, the operating parameters of the anilox roller are no longer directly adjusted. Instead, the calculation result of the actual flow index is indirectly corrected by adjusting the adjustment coefficient in the actual flow index calculation formula, making it more reflective of the true flow state under the influence of natural pulsation. This adjustment method is more precise and forward-looking.

[0127] This application's solution incorporates anilox roller operating parameters into multi-source data and decomposes all multi-source data to identify and summarize minute fluctuation components, thereby obtaining the natural pulsation characteristics in the aluminum foil coating process. It is precisely because these natural pulsation characteristics are captured and quantified that the system can identify those subtle, potentially undetectable, internal dynamics in the process that could lead to coating deviations. Through a pre-established mapping relationship between natural pulsation characteristics and coating difference, the system can predict potential coating deviations based on currently detected natural pulsation characteristics. Furthermore, instead of simply adjusting based on the deviation between the actual flow index and the target flow index, the system modifies the calculation logic of the flow index at a deeper level by adjusting the adjustment coefficient in the actual flow index calculation formula. This adjustment method allows the calculated result of the actual flow index to more accurately reflect the true flow behavior of water-based adhesives under the influence of natural pulsation, thereby achieving more refined and proactive control of the anilox roller operating parameters and effectively avoiding the accumulation of coating deviations caused by natural pulsation.

[0128] Through the above technical solution, this application overcomes the limitations of traditional methods in dealing with minor fluctuations within the process. By deeply analyzing multi-source data and extracting and utilizing natural pulsation characteristics, the system can identify potential trends in adhesive application deviation earlier and pre-compensate by adjusting the adjustment coefficient, rather than passively correcting after the deviation occurs. This significantly improves the sensitivity and foresight of the anilox roller adjustment method, further enhancing the stability of the adhesive application process and effectively ensuring the consistency of adhesive application. Furthermore, by incorporating the anilox roller operating parameters into the multi-source data, the system's perception of the process status becomes more comprehensive, thus providing a data foundation for more precise adjustments.

[0129] In some preferred embodiments, a specific example is given below. Suppose that in the aluminum foil coating process of pharmaceutical blister packaging, the viscosity of the water-based adhesive inside the tube, the ambient temperature, and other data exhibit slight, non-periodic fluctuations within a set time window. While these fluctuations are insufficient to immediately cause a significant deviation between the actual and target flow indices, their long-term accumulation may affect the coating quality.

[0130] Specifically, the system collects multi-source data in real time, including the viscosity of the water-based adhesive in the hose, ambient temperature, the temperature of the water-based adhesive in the reel, the local temperature of the anilox roller, production line speed, and anilox roller operating parameters. This data is then processed using signal processing techniques such as wavelet decomposition to extract minute fluctuations in instantaneous frequency, amplitude, and phase from each data set. These minute fluctuations are aggregated to form the natural pulsation characteristics of the current moment. For example, a weak oscillation at a specific frequency might be detected in the viscosity data, while the ambient temperature data might exhibit a slow drift.

[0131] The system will utilize a pre-established mapping relationship between natural pulsation features and adhesive application amount differences. This mapping relationship could be a neural network model trained on historical data, or a lookup table containing multiple natural pulsation patterns and their corresponding adhesive application amount deviations. For example, when the combined features of viscosity oscillation and temperature drift mentioned above are detected, the mapping relationship will indicate that this may result in a third adhesive application amount difference of +0.5 micrometers.

[0132] Based on this predicted difference in the third coating amount, the system adjusts the adjustment coefficients used to calculate the actual flow index. For example, if the preset calculation rule is "Actual flow index = Viscosity of water-based adhesive in the hose × (1 + C1 × (Temperature of water-based adhesive in the reel - Temperature of water-based adhesive in the target reel)) × (1 + C2 × (Local temperature of the anilox roller - Local temperature of the target anilox roller)) × (1 + C3 × (Ambient temperature - Target ambient temperature)) + C4 × Production line speed", the system may fine-tune the values ​​of C1, C2, or C3 to pre-offset or compensate for potential deviations caused by natural pulsation in the calculation of the actual flow index. In this way, even in the presence of natural pulsation, the calculated actual flow index can more accurately reflect the true flow state of the water-based adhesive, thereby making the subsequent adjustment of the anilox roller operating parameters more precise and stable, and effectively avoiding the accumulation of coating amount deviations.

[0133] This application further proposes steps for establishing a mapping relationship between natural pulsation characteristics and the difference in adhesive application amount to ensure the accuracy and reliability of this mapping relationship.

[0134] The steps to establish the mapping relationship between natural pulsation characteristics and the difference in adhesive application amount include:

[0135] Each historical data point obtained from the historical multi-source data in the historical aluminum foil coating process is decomposed, and the minute fluctuation components of each historical data point are extracted. All the minute fluctuation components are summarized to obtain the first natural pulsation feature in the historical aluminum foil coating process.

[0136] For each first natural pulsation feature, obtain the image of the second adhesive-coated area at the edge of the second aluminum foil after adhesive coating is completed;

[0137] Calculate the second adhesive width at the edge of the second aluminum foil based on the image of the second adhesive-coated area;

[0138] Calculate the difference in fourth adhesive application amount between the second adhesive application width and the preset standard adhesive application width;

[0139] Establish a one-to-one correspondence between each first natural pulsation feature and the corresponding fourth adhesive amount difference to obtain the mapping relationship between the natural pulsation feature and the adhesive amount difference.

[0140] Specifically, when processing historical multi-source data obtained from the historical aluminum foil coating process, each type of historical data is first decomposed. This historical multi-source data can include the viscosity of the water-based adhesive in the hose, ambient temperature, temperature of the water-based adhesive in the reel, local temperature of the anilox roller, and production line speed, as well as the anilox roller's operating parameters. The purpose of decomposition is to extract minute fluctuation components from this data. These fluctuation components typically represent unavoidable, random, or periodic natural pulsations in the process. For example, Fourier transform, wavelet analysis, or other signal processing techniques can be used to identify and extract these minute fluctuation components. Subsequently, all extracted minute fluctuation components are summarized to form the first natural pulsation feature of the historical aluminum foil coating process. This first natural pulsation feature is a comprehensive description of the overall minute fluctuation state of the process at a specific historical moment.

[0141] For each identified first natural pulsation feature, it is necessary to acquire an image of the second adhesive-coated area on the edge of the second aluminum foil at the corresponding moment after adhesive application. This is typically achieved by capturing images of the aluminum foil edge after adhesive application using an image acquisition device. The second adhesive-coated area image is crucial data for evaluating adhesive application quality.

[0142] Next, based on the acquired image of the second adhesive-coated area, the second adhesive width at the edge of the second aluminum foil is calculated. This can be achieved using image processing algorithms, such as identifying the boundary of the adhesive-coated area and measuring its lateral dimensions. The second adhesive width is an important indicator of the amount of adhesive applied.

[0143] Subsequently, the fourth adhesive application amount difference between the second adhesive application width and the preset standard adhesive application width is calculated. The preset standard adhesive application width is the ideal adhesive application width set according to process requirements. The fourth adhesive application amount difference reflects the degree of deviation between the actual adhesive application width and the standard adhesive application width under a specific first natural pulsation characteristic.

[0144] Finally, a one-to-one correspondence is established between each first natural pulsation feature and its corresponding fourth adhesive application amount difference. This relationship can be stored in a database, a lookup table, or modeled using a machine learning model to form the mapping relationship between the natural pulsation feature and the adhesive application amount difference. This mapping relationship serves as the basis for finding matching adhesive application amount differences during subsequent real-time adjustments.

[0145] This application's solution systematically collects and analyzes historical data to construct a mapping relationship between natural pulsation characteristics and the difference in adhesive application amount, thereby overcoming the limitations of the aforementioned basic solutions that lack quantification and prediction of the impact of natural pulsation on the process. Specifically, by decomposing historical multi-source data and extracting minute fluctuation components, the inherent natural pulsation characteristics of the process can be comprehensively captured. These first natural pulsation characteristics are correlated with the actual adhesive application quality (reflected by the second adhesive application width and the fourth difference in adhesive application amount), enabling the system to learn the possible deviations in adhesive application amount under different natural pulsation states. Therefore, when natural pulsation characteristics are detected in the real-time process, their impact on adhesive application amount can be predicted through this mapping relationship, thereby guiding the adjustment of the adjustment coefficient and achieving more precise and forward-looking control of the anilox roller operating parameters.

[0146] Through the above technical solution, this application can establish a quantitative relationship between natural pulsation characteristics and the difference in adhesive application amount, enabling the system to identify and predict the impact of minute fluctuations in the process on adhesive application quality. This significantly improves the stability and accuracy of the adhesive application process, avoiding the shortcomings of relying solely on real-time deviations for hysteresis adjustment. By pre-understanding the influence of natural pulsation, the system can intervene earlier, reducing fluctuations in adhesive application amount, thereby improving the adhesive application quality and production efficiency of pharmaceutical aluminum-plastic blister packaging and reducing the scrap rate.

[0147] In some preferred embodiments, a specific example is given below. Suppose that on a pharmaceutical aluminum-plastic blister packaging production line, it is necessary to establish a mapping relationship between natural pulsation characteristics and the difference in adhesive application amount.

[0148] First, multi-source data from the historical aluminum foil coating process is continuously recorded over a period of time, including the viscosity of the water-based adhesive in the adhesive tube, ambient temperature, temperature of the water-based adhesive in the adhesive tray, local temperature of the anilox roller, production line speed, and anilox roller operating parameters. For example, data is collected every minute and recorded for several weeks.

[0149] Next, each type of data in these historical multi-source datasets is decomposed. For example, wavelet decomposition can be performed on the viscosity data of water-based adhesives in hoses to extract minute fluctuation components such as instantaneous frequency, amplitude, and phase at different frequencies. This process is repeated for all data types, and these minute fluctuation components are aggregated to form a series of first natural pulsation features for the time series. For example, at a certain time T1, a specific first natural pulsation feature F1 is obtained.

[0150] Simultaneously, at each time point corresponding to the first natural pulsation feature, an image of the second adhesive-coated area at the edge of the second aluminum foil after adhesive coating is completed is acquired. For example, at time T1, image I1 is acquired.

[0151] Then, image processing is performed on image I1 to calculate the second adhesive coating width W1 at the edge of the second aluminum foil.

[0152] Subsequently, W1 is compared with the preset standard adhesive application width W_std, and the fourth adhesive application amount difference D1 = W1 - W_std is calculated.

[0153] Repeat the above process to calculate the corresponding fourth coating amount difference for the first natural pulsation feature at each historical moment.

[0154] Finally, a one-to-one correspondence is established between each first natural pulsation feature (e.g., F1, F2, ..., Fn) and the corresponding fourth adhesive application amount difference (e.g., D1, D2, ..., Dn), forming a mapping table or training a regression model. For example, when a natural pulsation feature similar to F1 is detected, the system can predict that the adhesive application amount will deviate by D1. In this way, the mapping relationship between natural pulsation features and adhesive application amount differences is successfully established, providing a data foundation for subsequent real-time adjustments.

[0155] This application further proposes a scheme to re-evaluate and adjust the actual flow index after adjusting the adjustment coefficient, so as to ensure the accuracy and stability of the coating process.

[0156] Following the steps described above, which involve adjusting the adjustment coefficient used to calculate the actual flow index based on the difference in the third adhesive application amount, this application further includes the following operations:

[0157] Calculate the current actual flow index of the water-based adhesive in the anilox roller cells based on the adjusted adjustment coefficient;

[0158] Compare the current actual liquidity index with the preset target liquidity index;

[0159] If there is a first deviation between the current actual flow index and the target flow index, the operating parameters of the anilox roller will be adjusted according to the magnitude of the first deviation.

[0160] Specifically, the current actual flow index of the water-based adhesive within the cells of the anilox roller is calculated based on the adjusted adjustment coefficient. This adjustment coefficient is a modified coefficient based on the natural pulsation characteristics and the difference in the third coating amount during the aluminum foil coating process. By using this modified adjustment coefficient, the true flow characteristics of the water-based adhesive under current operating conditions can be more accurately reflected. Subsequently, the calculated current actual flow index is compared with the preset target flow index. This comparison aims to assess whether the flow state of the water-based adhesive has reached the desired stable level after the adjustment coefficient correction. Finally, if there is a first deviation between the current actual flow index and the preset target flow index, the operating parameters of the anilox roller are adjusted according to the magnitude of this first deviation. This adjustment step is a fine-tuning correction for any residual deviations remaining after the adjustment coefficient correction, ensuring that the actual flow index of the water-based adhesive can accurately approach the target flow index, thereby optimizing the coating quality.

[0161] The proposed solution establishes a more robust closed-loop control mechanism by immediately recalculating and evaluating the actual flow index of the water-based adhesive after the adjustment coefficient is adjusted. Because the effect of the adjustment coefficient is verified in real time, and the anilox roller operating parameters are directly adjusted again for any potential residual deviations (i.e., the first deviation), the system can respond quickly and accurately to changes in operating conditions, avoiding situations where adjusting only the adjustment coefficient fails to completely eliminate flow index deviations. This secondary correction mechanism ensures that even with minor fluctuations, the actual flow index of the water-based adhesive can be precisely controlled within the target range, significantly improving the stability and consistency of the coating process.

[0162] Through the above technical solution, this application effectively solves the problem that the actual flow index may still deviate after adjusting the adjustment coefficient solely based on the natural pulsation characteristics. This solution significantly enhances the accuracy and stability of the entire coating process by introducing a recalculation and comparison of the current actual flow index, and a secondary adjustment of the anilox roller operating parameters based on the first deviation. Therefore, even under complex operating conditions, the flow index of the water-based adhesive can be ensured to remain at its optimal state, thereby effectively improving the quality and consistency of aluminum foil coating in pharmaceutical aluminum-plastic blister packaging processes and reducing the scrap rate.

[0163] In some preferred embodiments, it is assumed that during the aluminum foil coating process, the system fine-tunes the adjustment coefficients C1, C2, C3, and C4 for calculating the actual flow index based on the natural pulsation characteristics and the difference in the third coating amount. For example, C1 is adjusted from 0.01 to 0.011. After this adjustment, the system immediately recalculates the current actual flow index of the water-based adhesive using the new adjustment coefficients. Assume the recalculated current actual flow index is 120, while the preset target flow index is 118. At this point, there is a first deviation of 2 units. Based on the magnitude of this first deviation, the system automatically makes minor adjustments to the operating parameters of the anilox roller, such as the roller speed or pressure. For example, the roller speed can be slightly reduced to decrease the actual flow index of the water-based adhesive, bringing it closer to the target value. Through this secondary adjustment, it is ensured that even after the adjustment coefficients are corrected, the flow state of the water-based adhesive can be accurately calibrated to the optimal level, thereby guaranteeing the continuous stability of the coating quality.

[0164] Specifically, this application further defines the composition of the aforementioned natural pulsation features.

[0165] Specifically, the natural pulsation characteristics include minute fluctuations in instantaneous frequency, amplitude, and phase extracted within a set time window from at least one of the following data: viscosity of the water-based adhesive in the hose, ambient temperature, temperature of the water-based adhesive in the reel, local temperature of the anilox roller, and operating parameters of the anilox roller. These natural pulsation characteristics can be understood as systematic, periodic, or random fluctuations caused by minute changes in various factors during the aluminum foil coating process. These fluctuations are not caused by equipment malfunctions or operational errors, but are inherent to the process itself and are minute changes that are difficult to completely eliminate. To accurately capture these minute fluctuations, this application proposes extracting their instantaneous frequency, amplitude, and phase information from multiple key data sources. Specifically, these data include the viscosity of the water-based adhesive in the hose, ambient temperature, temperature of the water-based adhesive in the reel, local temperature of the anilox roller, and operating parameters of the anilox roller. In practical applications, at least one of these data can be monitored in real time, and within a preset time window, minute fluctuations in their instantaneous frequency, amplitude, and phase can be extracted using signal processing techniques (such as Fourier transform, wavelet analysis, etc.). Instantaneous frequency reflects the speed of fluctuation, amplitude reflects the intensity of fluctuation, and phase reflects the relative position of fluctuation over time. By comprehensively analyzing these components, the natural pulsation characteristics of the process can be fully and precisely depicted.

[0166] This application's solution, through precise definition of natural pulsation characteristics, enables the system to identify and quantify minute fluctuations caused by inherent process characteristics that are traditionally difficult to detect. These minute fluctuation components, such as instantaneous frequency, amplitude, and phase, can more precisely reflect the dynamic changes of the process. By establishing a mapping relationship between these refined natural pulsation characteristics and the adhesive application amount difference, the system can more accurately predict potential adhesive application amount deviations under specific natural pulsation conditions. Therefore, the adjustment of the control coefficient will no longer be based solely on macroscopic deviations but will take into account the microscopic dynamics within the process, thereby achieving more refined and proactive adjustments and effectively avoiding or mitigating the accumulation of adhesive application amount differences.

[0167] Through the above technical solution, this application enables a more comprehensive and in-depth understanding of the inherent dynamics of the aluminum foil coating process. The precise definition and quantification of natural pulsation characteristics allow the system to capture minute changes that traditional methods might overlook, thereby improving the accuracy of predicting coating amount deviations. This refined feature extraction and application helps establish a more accurate mapping relationship between natural pulsation characteristics and coating amount differences, thus enabling smarter and more effective adjustments to the adjustment coefficients. Ultimately, this improves the accuracy and stability of the anilox roller adjustment, reduces the scrap rate, and optimizes production efficiency.

[0168] Specifically, in some embodiments of the above-mentioned program-controlled anilox roller adjustment method, in order to accurately calculate the actual flow index of the water-based adhesive in the anilox roller cells, this application defines the preset calculation rules in detail.

[0169] The preset calculation rule is: Actual flow index = viscosity of water-based adhesive in hose × (1 + C1 × (temperature of water-based adhesive in rubber tray - temperature of water-based adhesive in target rubber tray)) × (1 + C2 × (local temperature of anilox roller - local temperature of target anilox roller)) × (1 + C3 × (ambient temperature - target ambient temperature)) + C4 × production line speed;

[0170] C1, C2, C3, and C4 are adjustment coefficients used to calculate the actual flow index.

[0171] The actual flow index refers to the flow characteristics of water-based adhesives within the cells of the anilox roller, reflecting the adhesive's filling, transfer, and release capabilities within the cells. The viscosity of the water-based adhesive within the hose is a core parameter affecting its flowability, directly reflecting the adhesive's physical properties. Ambient temperature, the temperature of the water-based adhesive in the reel, and the local temperature of the anilox roller are all important external factors influencing the viscosity and flow behavior of the water-based adhesive. Production line speed is directly related to the dynamic characteristics and time effects of the coating process.

[0172] Specifically, the target temperature of the water-based adhesive in the target reel, the target local temperature of the anilox roller, and the target ambient temperature are preset temperature values ​​under ideal or standard operating conditions, used to measure the impact of the deviation between the actual temperature and the ideal temperature on the flow index. Adjustment coefficients C1, C2, C3, and C4 are weighting factors used to quantify the degree of influence of different parameters on the actual flow index. These coefficients can be set and adjusted based on actual production experience, experimental data, or optimization algorithms to ensure the accuracy and applicability of the calculation results. For example, C1 is used to adjust the impact of the water-based adhesive temperature deviation in the reel on the flow index, C2 is used to adjust the impact of the local temperature deviation of the anilox roller, C3 is used to adjust the impact of the ambient temperature deviation, and C4 is used to adjust the direct impact of the production line speed on the flow index.

[0173] This application's solution uses the viscosity of the water-based adhesive inside the hose as a basic parameter, and combines it with several key influencing factors such as ambient temperature, the temperature of the water-based adhesive in the reel, the local temperature of the anilox roller, and the production line speed to construct a comprehensive mathematical model to calculate the actual flow index. This model, by introducing adjustment coefficients C1, C2, C3, and C4, can quantify the impact of each factor deviating from the target value on the flowability of the water-based adhesive. For example, when the temperature of the water-based adhesive in the reel is higher than the target temperature, the term (temperature of water-based adhesive in reel - temperature of target reel) is positive. If C1 is positive, it will increase the actual flow index, which conforms to the physical law that viscosity decreases and flowability increases with increasing temperature. In this way, the preset calculation rule can dynamically reflect the true flow state of the water-based adhesive under different operating conditions, providing an accurate basis for subsequent adjustment of the anilox roller operating parameters.

[0174] Through the above technical solution, this application provides a precise and quantifiable preset calculation rule for calculating the actual flow index of water-based adhesives within the cells of anilox rollers. This rule comprehensively considers multi-source data and introduces adjustable coefficients, making the calculation of the actual flow index closer to real-world operating conditions, thereby improving the ability to perceive changes in the flowability of water-based adhesives. Consequently, it can more accurately identify the deviation between the actual flow index and the target flow index, providing a more reliable decision-making basis for subsequent adjustments to the anilox roller operating parameters, facilitating more refined adhesive coating control, and improving the stability and consistency of coating quality.

[0175] See Figure 2 The specific implementation of this application also discloses a program-controlled anilox roller adjustment system applied to the aluminum-plastic blister packaging process of pharmaceuticals, including: an acquisition module 1, a calculation module 2, a comparison module 3, and an adjustment module 4.

[0176] Module 1 is used to acquire the following multi-source data in real time during the aluminum foil coating process: viscosity of water-based adhesive in the adhesive tube, ambient temperature, temperature of water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed.

[0177] Calculation module 2 is used to calculate the actual flow index of water-based adhesive in the anilox roller cavity based on the multi-source data and preset calculation rules;

[0178] Comparison module 3 is used to compare the actual flow index with the preset target flow index;

[0179] Adjustment module 4 is used to adjust the operating parameters of the anilox roller according to the magnitude of the deviation between the actual flow index and the target flow index.

[0180] This system integrates multiple functional modules to achieve intelligent and real-time adjustment of the anilox roller coating process in pharmaceutical aluminum-plastic blister packaging. Module 1 is responsible for comprehensively sensing key environmental and process parameters affecting adhesive flowability; Module 2, based on this real-time data, accurately assesses the actual flow state of the adhesive at the moment of coating; Module 3 makes an immediate judgment on the assessment results; and Module 4, based on the judgment results, precisely intervenes in the operating parameters of the anilox roller. This collaborative working mechanism aims to overcome the lag and inaccuracy of traditional control schemes in dealing with complex and changing production environments, ensuring the stability and consistency of the coating amount, thereby significantly improving the sealing quality and production efficiency of pharmaceutical packaging.

[0181] The detailed description of the program-controlled anilox roller adjustment method has been described in the above embodiments and will not be repeated here. It should be emphasized that the program-controlled anilox roller adjustment system disclosed in this application provides a physical entity to perform the adjustment process by converting the above method steps into specific hardware or software modules.

[0182] Specifically, the acquisition module 1 can be configured to include a series of sensors and data acquisition units. For example, the viscosity of the water-based adhesive inside the hose can be measured in real time using an online viscosity sensor; the ambient temperature can be monitored using a temperature sensor array; the temperature of the water-based adhesive inside the reel can be acquired using an immersion thermocouple or an infrared sensor; the local temperature of the anilox roller can be detected using a non-contact infrared thermometer; and the production line speed can be acquired in real time using an encoder or photoelectric sensor. These sensors can be deployed independently and transmit data to a central data processing unit via wired or wireless means. This central data processing unit is part of the acquisition module 1 and is responsible for data preprocessing and standardization. Alternatively, the acquisition module 1 can be an integrated multi-functional sensor unit capable of simultaneously acquiring multiple types of data and outputting them through a unified interface.

[0183] The calculation module 2 can be implemented as a microprocessor, digital signal processor (DSP), or programmable logic controller (PLC), internally storing preset calculation rules. This module receives real-time multi-source data from the acquisition module 1 and, based on a preset mathematical model or algorithm, calculates the actual flow index of the water-based adhesive within the anilox roller cells. For example, the calculation rule can be a multivariable function, deriving the flow index through weighted summation, product, or more complex nonlinear operations on the input data. The calculation module 2 can be designed as a stand-alone calculation unit or as part of the main controller of the entire control system.

[0184] The comparison module 3 can be integrated into the calculation module 2 or exist as a separate logical unit. Its function is to receive the actual flow index output by the calculation module 2 and compare it with a preset target flow index. This comparison can be determined by a simple numerical difference or by setting an allowable deviation range to determine if a deviation exists. For example, when the actual flow index exceeds the preset upper or lower limits of the target flow index, it is determined that a deviation exists.

[0185] The adjustment module 4 can consist of a series of actuators and drive circuits, used to convert control commands into physical adjustments to the operating parameters of the anilox roller. For example, when the comparison module 3 detects a deviation, the adjustment module 4 can generate a corresponding control signal according to a preset control strategy (such as a PID algorithm), driving a stepper motor to adjust the pressure between the anilox roller and the printing plate roller, or changing the speed of the anilox roller through a frequency converter, or adjusting the angle and pressure of the doctor blade through a pneumatic or hydraulic system. These actuators can be directly coupled to the mechanical structure of the anilox roller to achieve precise control of the amount of adhesive applied. The adjustment module 4 can be an independent control unit or an output interface integrated into the main controller.

[0186] The program-controlled anilox roller adjustment system proposed in this application aims to solve the technical problems of inaccurate glue application control, slow response, and failure to fully consider influencing factors in existing pharmaceutical aluminum-plastic blister packaging processes. Traditional control systems often rely on single parameter feedback or fixed programs, making it difficult to cope with complex operating conditions such as ambient temperature fluctuations, sensitivity to new adhesives, and localized heating of the anilox roller, resulting in unstable glue application and affecting product quality.

[0187] This system achieves refined management of the adhesive coating process by introducing a collaborative working mechanism of acquisition module 1, calculation module 2, comparison module 3, and adjustment module 4. Acquisition module 1 can collect multi-source data in real time, including the viscosity of the water-based adhesive in the adhesive tube, ambient temperature, temperature of the water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed, overcoming the limitations of incomplete information acquisition in existing technologies. Based on this multi-source data, calculation module 2 calculates the actual flow index of the water-based adhesive within the cells of the anilox roller using preset calculation rules, thus accurately reflecting the true state of the adhesive at the moment of coating and avoiding the lag problem of traditional single-point viscosity feedback control. Comparison module 3 and adjustment module 4 ensure that the system can adjust the anilox roller operating parameters in a timely and accurate manner based on the deviation between the actual flow index and the target flow index.

[0188] Compared to existing technologies, this system can more comprehensively and accurately perceive and evaluate key parameters in the adhesive coating process, and make real-time, adaptive adjustments. This not only effectively solves the problem of adhesive coating fluctuations and improves the sealing quality and pass rate of pharmaceutical packaging, but also reduces defective product rates and production waste, significantly improving production efficiency and economic benefits. Therefore, this system represents a significant technological advancement and innovation in the field of adhesive coating control for pharmaceutical aluminum-plastic blister packaging.

[0189] The above description is merely an embodiment of this application and is not intended to limit the scope of protection of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of protection of this application.

Claims

1. A program-controlled anilox roller adjustment method, applied to the aluminum-plastic blister packaging process for pharmaceuticals, characterized in that, include: The following multi-source data are acquired in real time during the aluminum foil coating process: viscosity of water-based adhesive in the adhesive tube, ambient temperature, temperature of water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed. Based on the multi-source data and preset calculation rules, the actual flow index of the water-based adhesive in the anilox roller cavity is calculated. Compare the actual flow index with the preset target flow index; When there is a deviation between the actual flow index and the target flow index, the operating parameters of the anilox roller are adjusted according to the magnitude of the deviation. The actual flow index refers to the flow characteristics of the water-based adhesive within the cells of the anilox roller. The preset calculation rule is: Actual flow index = viscosity of water-based adhesive in hose × (1 + C1 × (temperature of water-based adhesive in rubber tray - temperature of water-based adhesive in target rubber tray)) × (1 + C2 × (local temperature of anilox roller - local temperature of target anilox roller)) × (1 + C3 × (ambient temperature - target ambient temperature)) + C4 × production line speed; Where C1, C2, C3, and C4 are adjustment coefficients used to calculate the actual flow index; The step of adjusting the anilox roller operating parameters according to the magnitude of the deviation when the actual flow index deviates from the target flow index also includes: Obtain an image of the coated area at the edge of the aluminum foil after the coating process is completed, corresponding to the adjustment of the anilox roller's operating parameters. Calculate the adhesive width at the edge of the aluminum foil based on the image of the adhesive-coated area; Calculate the difference in glue application amount between the glue application width and the preset glue application standard width, and determine whether the difference in glue application amount is within the preset range; When the difference in adhesive application amount is outside the preset range, the operating parameters of the anilox roller are adaptively corrected according to the magnitude of the difference in adhesive application amount, so that the difference in adhesive application amount between the edge of the aluminum foil after subsequent adhesive application and the preset standard adhesive application width falls back to within the preset range. When the aluminum foil coating process is stable and the difference in coating amount between the coating width at the edge of the aluminum foil and the preset coating standard width is within a preset range, perform the following operations periodically at set intervals: The operating parameters of the anilox roller are fine-tuned according to the preset exploratory disturbance rules; Obtain an image of the first coated area at the edge of the first aluminum foil after the coating process is completed, corresponding to the fine-tuning of the anilox roller's operating parameters. Calculate the first adhesive width at the edge of the first aluminum foil based on the image of the first adhesive-coated area; Calculate the difference in the first adhesive application amount between the first adhesive application width and the preset standard adhesive application width; Compare the difference in the first amount of adhesive applied, the width of the adhesive applied to the edge of the aluminum foil before fine-tuning, and the difference in the second amount of adhesive applied to the preset standard width. Adjust the adjustment coefficient used to calculate the actual flow index based on the difference between the first and second adhesive application amounts.

2. The method for adjusting anilox rollers based on program control according to claim 1, characterized in that, The specific steps for real-time temperature monitoring of the water-based adhesive in the adhesive tray during the aluminum foil coating process include: The first radiation intensity value of the water-sensitive infrared band, the second radiation intensity value of the polymer-sensitive infrared band, and the third radiation intensity value of the substrate reference infrared band were collected from the adhesive tray. Based on the first radiation intensity value, the second radiation intensity value, and the third radiation intensity value, the water-based adhesive activity index and the water-based adhesive residual layer presence index are calculated. The water-based adhesive activity index reflects the activity level or concentration of active ingredients in the water-based adhesive and is calculated based on the first radiation intensity value and the second radiation intensity value. The water-based adhesive residual layer presence index reflects the thickness of the water-based adhesive layer in the adhesive tray and is calculated based on the first radiation intensity value, the second radiation intensity value, and the third radiation intensity value. The true temperature of the water-based adhesive in the adhesive tray is calculated based on the activity index and the residual layer presence index of the water-based adhesive. The actual temperature of the water-based adhesive in the glue tray is defined as the temperature of the water-based adhesive in the glue tray.

3. The method for adjusting anilox rollers based on program control according to claim 1, characterized in that, The multi-source data also includes anilox roller operating parameters; After acquiring multi-source data in real time during the aluminum foil coating process, the following is also included: Each data point in the multi-source data is decomposed, and the minute fluctuation components of each data point are extracted. All the minute fluctuation components are summarized to obtain the natural pulsation characteristics in the aluminum foil coating process. Based on the natural pulsation characteristics, a matching third glue application amount difference is found from the mapping relationship between natural pulsation characteristics and glue application amount difference; Adjust the adjustment coefficient used to calculate the actual flow index based on the difference in the third coating amount.

4. The method for adjusting anilox rollers based on program control according to claim 3, characterized in that, The steps to establish the mapping relationship between natural pulsation characteristics and the difference in adhesive application amount include: Each historical data point obtained from the historical multi-source data in the historical aluminum foil coating process is decomposed, and the minute fluctuation components of each historical data point are extracted. All the minute fluctuation components are summarized to obtain the first natural pulsation feature in the historical aluminum foil coating process. For each first natural pulsation feature, obtain the image of the second adhesive-coated area at the edge of the second aluminum foil after adhesive coating is completed; Calculate the second adhesive width at the edge of the second aluminum foil based on the image of the second adhesive-coated area; Calculate the difference in fourth adhesive application amount between the second adhesive application width and the preset standard adhesive application width; Establish a one-to-one correspondence between each first natural pulsation feature and the corresponding fourth adhesive amount difference to obtain the mapping relationship between the natural pulsation feature and the adhesive amount difference.

5. The method for adjusting anilox rollers based on program control according to claim 3, characterized in that, The step of adjusting the adjustment coefficient used to calculate the actual flow index based on the difference in the third adhesive application amount further includes: Calculate the current actual flow index of the water-based adhesive in the anilox roller cells based on the adjusted adjustment coefficient; Compare the current actual liquidity index with the preset target liquidity index; If there is a first deviation between the current actual flow index and the target flow index, the operating parameters of the anilox roller will be adjusted according to the magnitude of the first deviation.

6. The method for adjusting anilox rollers based on program control according to any one of claims 3 to 5, characterized in that, The natural pulsation characteristics include minute fluctuations in instantaneous frequency, amplitude, and phase extracted within a set time window from at least one of the following data: viscosity of the water-based adhesive in the hose, ambient temperature, temperature of the water-based adhesive in the reel, local temperature of the anilox roller, and operating parameters of the anilox roller.

7. A program-controlled anilox roller adjustment system, applied in pharmaceutical aluminum-plastic blister packaging process, for performing the method as described in claim 1, characterized in that, include: The acquisition module is used to acquire the following multi-source data in real time during the aluminum foil coating process: viscosity of water-based adhesive in the adhesive tube, ambient temperature, temperature of water-based adhesive in the adhesive tray, local temperature of the anilox roller, and production line speed. The calculation module is used to calculate the actual flow index of the water-based adhesive in the anilox roller cavity based on the multi-source data and preset calculation rules. The comparison module is used to compare the actual flow index with the preset target flow index. The adjustment module is used to adjust the operating parameters of the anilox roller according to the magnitude of the deviation between the actual flow index and the target flow index. The actual flow index refers to the flow characteristics of the water-based adhesive within the cells of the anilox roller. The preset calculation rule is: Actual flow index = viscosity of water-based adhesive in hose × (1 + C1 × (temperature of water-based adhesive in rubber tray - temperature of water-based adhesive in target rubber tray)) × (1 + C2 × (local temperature of anilox roller - local temperature of target anilox roller)) × (1 + C3 × (ambient temperature - target ambient temperature)) + C4 × production line speed; C1, C2, C3, and C4 are adjustment coefficients used to calculate the actual flow index.

Images